Halogen-free flame-retardant polymer composition comprising piperazine based intumescent flame retardant

ABSTRACT

Halogen-free flame-retardant polymer composition, preparation method and use thereof are provided. The composition comprises a propylene polymer, a thermoplastic elastomer, and an intumescent flame retardant system comprising a piperazine component. The obtained halogen-free flame-retardant polymer composition is used to make wire or cable sheath.

CROSS REFERENCE TO RELATED APPLICATION

The present application is the national phase of PCT Patent ApplicationNo. PCT/CN2011/076057 filed Jun. 21, 2011, the entire content of whichis incorporated by reference herein.

FIELD OF THE INVENTION

Embodiments of the invention relate to compositions for wire and cable(W&C) applications. In one aspect, the invention relates tothermoplastic compositions for use in W&C sheathings, e.g., protectivejackets and insulation, which are flame retardant and halogen-free.

BACKGROUND OF THE INVENTION

A key challenge in the wire and cable (W&C) flame resistant sheathingmarket is to provide a flame retardant composition for flexible wiringuse in low voltage personnel electronic applications, including consumerelectronics such as cell phone charger wire and computer data, power andaccessory cords. Although current insulation materials may provide abalance of mechanical properties and flexibility, the retention onelongation after high temperature heat aging is poor and the wetelectrical resistance is low.

Compositions fabricated using a single polymeric system such aspolyolefins or thermoplastic elastomers (TPE) such as thermoplasticurethanes lack the necessary specifications to meet all necessaryrequirements for the flame retardant (FR) insulation market.Thermoplastic polyurethane (TPU)-based, halogen-free flame retardant(HFFR) compositions are typically used for wire insulation/cable jacketsfor personal electronics to replace halogen-containing polymericmaterials. Cable sheathing formed from TPU-based flame retardant (FR)polymer compositions generally fulfill heat deformation testing(UL-1581) requirements at 150° C. that are important in certain W&Capplications and which, generally, cannot be achieved with sheathingformed from un-crosslinked polyolefin as a matrix polymer. However,major disadvantages of TPU-based FR compositions is insulationresistance (IR) failure, poor smoke density, high material density, andthe high cost of TPU as a raw material.

Using polyolefins to replace TPU could potentially solve problems ofTPU-based FR compositions. However, polyolefins or polyolefinelastomer-based HFFR compositions typically suffer from a dramatic dropof heat deformation properties due to a lower melting temperaturecompared to TPU-based FR compositions, particularly at hightemperatures, e.g., 150° C. In addition, the use of polyolefincomponents typically decrease overall FR performance due to thecarbon-hydrogen structure. Consequently, it is difficult forpolyolefin-based HFFR compositions to afford a high level of flameretardancy with balanced mechanical properties.

SUMMARY OF THE INVENTION

In embodiments of the invention, a halogen-free, flame retardantcomposition is provided, which will process easily to make a wire andcable (W&C) sheathing that will pass both the VW-1 flame retardancy testand the UL1581-2001 heat deformation test at 150° C. while at the sametime having a secant modulus below 35000 psi, and exhibiting goodtensile and flexibility properties, and providing high wet electrical(insulation) resistance. In one embodiment, the composition comprises:

-   -   A. A polyolefin base resin based on a propylene polymer, for        example, a propylene homopolymer, propylene random copolymer        (RCP), a propylene impact modified polymer (ICP), or a mixture        thereof, as the primary phase, being at least 5, and more        preferred at greater than 10, wt % of the formulation;    -   B. One or more thermoplastic elastomers (TPE);    -   C. A flame retardant system based on nitrogen and/or        phosphorus-based, intumescent halogen-free flame retardant        comprising a piperazine component; and    -   D. Optional additive package.

In embodiments of the composition, the component “A” polyolefin baseresin is at least 5 wt % and preferably greater than 10 wt %, thecomponent “B” TPE is at about 1-80, and preferably at least 10, wt %,the component “C” flame retardant system is at least 10, and preferablyat least 20, wt %, and the component “D” optional additives, whenpresent, are from 0.1-20 wt %, the wt % based on the total weight of theformulation.

The invention provides a halogen-free, flame-retardant polymercomposition for wire and cable (W&C) insulation use, and for replacementof polyvinyl chloride (PVC) compositions innon-PVC, halogen-free and/orhalogen-free, flame retardant markets. The present compositions areparticularly useful in flexible wiring applications, e.g., consumerelectronics such as cell phone charger wire, etc. The compositions ofthe invention overcome drawbacks of existing technologies y providingthe desired balance of mechanical properties, high flame retardancy andprocessability including good heat stability and high flexibility, andhighly improved wet insulation resistance and wet electrical properties,heat aging performance and heat deformation.

The present blends of a polyolefin including propylene and thermoplasticelastomer(s) (TPE) such as random and block-copolymers of polyolefinscombined with an intumescent nitrogen-phosphorous (N—P) type,non-halogen, flame-retardant (FR) additive system comprising apiperazine component, achieve an unexpectedly synergy that provides wireand cable (W&C) sheathing made from the FR compositions of the inventionwith an exceptionally excellent balance of good mechanical properties,including tensile elongations greater than 150% and 200% (ASTM D638),tensile stress greater than 10 MPa, and tensile strengths greater than800 psi, excellent FR performance to pass the VW-1 test, ease ofextrusion, improved heat deformation performance to pass the UL1581-2001test at up to 150° C. (less than 50%), improved wet electricalresistance, good thermal aging performance, flexibility and low smokedensity solution compared to other non-halogen FR composites used forW&C insulation. The PP/TPE compositions of the invention have superiormechanical properties and flexibility compared to TPU-basedhalogen-free, flame retarding materials and a much lower density andhigher wet insulation (electrical) resistance than TPU-basedhalogen-free, flame retardant (HFFR) compositions, and the raw materialcost is significantly decreased. Metal hydrate-based TPU, TPEs orpolyolefin compounds, and intumescent-based polyolefin compounds do notprovide a proper balance of FR performance and mechanical propertieswith heat deformation and wet insulation resistance as the presentblends of polyolefins such as polypropylene with elastomers or PO-basedrandom or block co-polymers as provided herein. The present compositionspass the criteria for W&C applications, including passing the VW-1 flameretardancy test, measuring a secant modulus (flexibility) at below 35000psi, and heat deformation at minimum 80° C., and in particularembodiments, at 121° C. and at 150° C., at <50%. The presenthalogen-free FR thermoplastic compositions also meet North American,European and Japanese specifications including but not limited to UL-62,HD21.14 and JCS 4509 standards and specifications.

Advantageously, the present compositions do not require and, inembodiments, do not include a compatibilizer (e.g., functional polymer)between the PP and thermoplastic elastomer components, which provides acost effective solution to other compositions and processes that requiredifferent functional polymers as compatibilizers to achieve the blends.The inventive compositions also do not employ any crosslinking step(i.e., neither post-curing nor dynamic crosslinking), thus providing asimplified process and improved material processability over othertechnologies that utilize a crosslinking mechanism. By replacing aportion of the single polymeric content (PP and/or other TPE) of otherknown formulations with a thermoplastic elastomer (e.g., random or blockpolyolefin copolymers), the blends in combination with the intumescentnitrogen-phosphorous type FR additive system provide an excellentbalance of mechanical properties (e.g., elongations >150%, tensilestrengths >800 psi), improved heat deformation temperatures, good burnperformance, and improved wet electrical performance. In addition, byblending in low cost polyolefins with the TPE, the cost of the plasticis significantly reduced allowing new formulation latitude for both TPEand polyolefin end uses for halogen-free FR plastics. The compositionsof the invention also provide a solution for polyolefin-based HFFRproducts by affording superior mechanical properties and heatdeformation performance while not compromising the overall FRperformance.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Definitions

All references to the Periodic Table of the Elements refer to thePeriodic Table of the Elements published and copyrighted by CRC Press,Inc., 2003. Also, any references to a Group or Groups shall be to theGroup or Groups reflected in this Periodic Table of the Elements usingthe IUPAC system for numbering groups. Unless stated to the contrary,implicit from the context, or customary in the art, all parts andpercents (%) are based on weight and all test methods are current as ofthe filing date of this disclosure. For purposes of U.S. patentpractice, the contents of any referenced patent, patent application orpublication are incorporated by reference in their entirety (or itsequivalent U.S. version is so incorporated by reference) especially withrespect to the disclosure of synthetic techniques, product andprocessing designs, polymers, catalysts, definitions (to the extent notinconsistent with any definitions specifically provided in thisdisclosure), and general knowledge in the art.

The numerical ranges in this disclosure are approximate, and thus mayinclude values outside of the range unless otherwise indicated.Numerical ranges include all values from and including the lower and theupper values, in increments of one unit, provided that there is aseparation of at least two units between any lower value and any highervalue. As an example, if a compositional, physical or other property,such as, for example, molecular weight, weight percentages, etc., isfrom 100 to 1,000, then the intent is that all individual values, suchas 100, 101, 102, etc., and sub ranges, such as 100 to 144, 155 to 170,197 to 200, etc., are expressly enumerated. For ranges containing valueswhich are less than one or containing fractional numbers greater thanone (e.g., 1.1, 1.5, etc.), one unit is considered to be 0.0001, 0.001,0.01 or 0.1, as appropriate. For ranges containing single digit numbersless than ten (e.g., 1 to 5), one unit is typically considered to be0.1. These are only examples of what is specifically intended, and allpossible combinations of numerical values between the lowest value andthe highest value enumerated, are to be considered to be expresslystated in this disclosure. Numerical ranges are provided within thisdisclosure for, among other things, the amounts of various components inthe inventive composition, the amount of the various components in theFR component of the inventive compositions, and the variouscharacteristics and properties by which these compositions and the W&Csheathing made from these compositions are defined.

“Cable” and like terms mean at least one wire or optical fiber within asheath, e.g., an insulation covering or a protective outer jacket.Typically, a cable is two or more wires or optical fibers boundtogether, typically in a common insulation covering and/or protectivejacket. The individual wires or fibers inside the sheath may be bare,covered or insulated. Combination cables may contain both electricalwires and optical fibers. The cable, etc. can be designed for low,medium and high voltage applications. Typical cable designs areillustrated in U.S. Pat. Nos. 5,246,783, 6,496,629 and 6,714,707.

“Composition”, “formulation” and like terms means a mixture or blend oftwo or more components.

An “elastomer” is a rubber-like polymer which can be stretched to atleast twice its original length and which retracts very rapidly toapproximately its original length when the force exerting the stretchingis released. An elastomer has an elastic modulus of about 10,000 psi(68.95 MPa) or less and an elongation usually greater than 200% in theuncrosslinked state at room temperature using the method of ASTMD638-72.

“Halogen-free” and like terms mean that the compositions of theinvention are without or substantially without halogen content, i.e.,contain <2000 mg/kg of halogen as measured by ion chromatography (IC) orsimilar analytical method. Halogen content of less than this amount isconsidered inconsequential to the efficacy of the composition as a wireor cable covering.

“Interpolymer” means a polymer prepared by the polymerization of atleast two different monomers. This generic term includes copolymers,usually employed to refer to polymers prepared from two differentmonomers, and polymers prepared from more than two different monomers,e.g., terpolymers, tetrapolymers, etc.

“Intumescent flame retardant” and like terms means a flame retardantthat yields a foamed char formed on a surface of a polymeric materialduring fire exposure.

“Olefin-based polymer” and like terms means a polymer containing, inpolymerized form, a majority weight percent (wt %) of an olefin, forexample ethylene or propylene, based on the total weight of the polymer.Nonlimiting examples of olefin-based polymers include ethylene-basedpolymers and propylene-based polymers.

The term “polymer” (and like terms) is a macromolecular compoundprepared by reacting (i.e., polymerizing) monomers of the same ordifferent type. “Polymer” includes homopolymers and interpolymers.

“Polymer blend” and like terms mean a blend of two or more polymers.Such a blend may or may not be miscible. Such a blend may or may not bephase separated. Such a blend may or may not contain one or more domainconfigurations, as determined from transmission electron spectroscopy,light scattering, x-ray scattering, and any other method known in theart.

“Polyolefin”, “PO” and like terms mean a polymer derived from simpleolefins. Many polyolefins are thermoplastic and for purposes of thisinvention, can include a rubber phase. Representative polyolefinsinclude polyethylene, polypropylene, polybutene, polyisoprene and theirvarious interpolymers.

“Resistance” is defined as the opposition of a material to the flow ofan electric current based on the shape (area and length) and resistivityof the material. Resistance indicates the degree of electricalcontinuity across a surface or from surface to ground, and may alsoindicate the ability of an object to dissipate a charge. The term“surface resistance” is defined as the ratio of dc voltage to thecurrent flowing between two electrodes of a specified configuration thatcontact the same side of a material. Resistance and surface resistanceare expressed in ohms.

“Surface resistivity” is defined as the ratio of the dc voltage drop perunit length to the surface current per unit width for electric currentflowing across a surface. Surface resistivity is a material parameterwhen the material is a thin film of constant thickness. In effect, thesurface resistivity is the resistance between two opposite sides of asquare, and is independent of the size of the square (where the size isgreater than the film thickness) or its dimensional units. Surfaceresistivity is expressed in ohms per square (Ω/sq) and is traditionallyused to evaluate insulative materials for electrical applications.

Tensile elongation at break is measured in accordance with ASTM D638.Tensile strength at break is measured in accordance with ASTM D638.

“Volume resistance” is defined as the ratio of dc voltage to currentpassing between two electrodes (of a specified configuration) thatcontact opposite sides of the material of the object under test. Volumeresistance is reported in ohms.

“Volume resistivity” is defined as the ratio of the dc voltage drop perunit thickness to the amount of current per unit area passing throughthe material. Volume resistivity indicates how readily a materialconducts electricity through the bulk of the material. Volumeresistivity is expressed in ohm-centimeters (Ω-cm).

“VW-1” is an Underwriters' Laboratory (UL) flame rating for wire andsleeving, and denotes “Vertical Wire, Class 1,” the highest flame ratinga wire or sleeve can be given under the UL 1441 specification. The testis performed by placing the wire or sleeve in a vertical position. Aflame is set underneath for a period of time and then removed, andcharacteristics of the sleeve are noted. The VW-1 flame test can bedetermined according to Method 1080 of UL-1581.

“Wire” and like terms mean a single strand of conductive metal, e.g.,copper or aluminum, or a single strand of optical fiber.

In embodiments of the invention, the compositions comprise a bi-resinsystem of a component (A) a polyolefin base resin, including but notlimited to a polypropylene-based polymer as the primary phase, and acomponent (B) thermoplastic elastomer(s) (TPE) blended with a component(C) a flame retardant (FR) system and, optionally, a component (D)optional additives. The FR system includes a nitrogen/phosphorus-based,intumescent halogen-free flame retardant comprising a piperazinecomponent (e.g., FP2100J and Budit 3167). The optional additive packagecan comprise one or more conventional additives for compositions fromwhich flame retardant wire and cable sheaths are prepared, e.g.,antioxidants, UV stabilizers, colorants, processing aids, and the like.

Polyolefin (PO) Base Resin/Matrix. The polyolefin (PO) base resin(matrix) component (A) includes a propylene polymer (also calledpolypropylene) as the primary phase. The polyolefin base resin componentis at least 5, at least 10, and preferably at least 20 wt %, andtypically in a range of 5-80, 10-60, 10-40, and 20-40, wt % of thecomposition. Preferably the polyolefin base resin component is greaterthan 20 wt % and less than or equal to 30 wt % of the composition.

“Propylene polymer,” “propylene” and like terms mean a polymer thatcomprises a majority wt % polymerized propylene monomer (based on thetotal amount of polymerizable monomers), and optionally may comprise atleast one polymerized comonomer. Propylene polymers of the inventioninclude propylene homopolymers as well as random and impact-modifiedcopolymers of propylene, and mixtures thereof. The propylene polymer canbe isotactic, syndiotactic or atactic polypropylene. “Propylenehomopolymer” and similar terms mean a polymer consisting solely oressentially all of units derived from a propylene monomer at greaterthan 65 wt %. “Propylene copolymer” and similar terms mean a polymercomprising units derived from propylene and ethylene and/or one or moreunsaturated comonomers. The term “copolymer” includes terpolymers,tetrapolymers, etc. For propylene copolymers, the comonomer content ispreferably less than 35, preferably 2 to 30, and preferably 5 to 20, wt%. The melt flow rate (MFR, as measured by ASTM D1238 at 230° C./2.16kg) of the propylene polymers is preferably less than 20 g/10 min., andpreferably at least 1, 1.5, and most preferably at least 1.9, g/10 min.,and typically up to 2, 5, 7, most preferably up to 12, g/10 min., inorder to achieve good processability and mechanical properties balance.The propylene polymer preferably exhibits a peak melting point(T_(max)), as determined by DSC, of 100-170° C., and preferably higherthan 140° C. Polypropylene homopolymers are commercially available andinclude DOW polypropylene homopolymer resins DOW 5D49 (MFR=38 g/10 min),DOW 5D98 (MFR=3.4 g/10 min), DOW 5E16S (MFR=35 g/10 min), and DOW 5E89(MFR=4.0 g/10 min), among others, all available from The Dow ChemicalCompany.

Propylene homopolymers are a readily available and competitively pricedmaterial. However, random and impact copolymers are preferred forcompatibility of propylene and ethylene polymers, and improved physicaland mechanical properties for the resulting articles (such as improvedtear, dart impact, or puncture resistance in films). In comparison withpropylene homopolymers, random propylene copolymers exhibit improvedoptical properties (i.e., clarity and haze), improved impact resistance,increased flexibility and a decreased melting point. Random propylenecopolymers are used in many applications, typically those that requireimproved clarity and/or impact resistance (as compared to propylenehomopolymers).

“Random copolymer” means a copolymer in which the monomer is randomlydistributed across the polymer chain. Random propylene copolymerstypically comprise 90 or more mole % units derived from propylene, withthe remainder of the units derived from units of at least one α-olefin.The presence of the comonomer in the copolymer changes thecrystallinity, and thus the physical properties, of the propylene. Theα-olefin component of the random propylene copolymer is preferablyethylene (considered an α-olefin for purposes of this invention) or aC₄₋₂₀ linear, branched or cyclic α-olefin. Examples of C₄₋₂₀ α-olefinsinclude 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene,1-dodecene, 1-tetradecene, 1-hexadecene, and 1-octadecene. The α-olefinsalso can contain a cyclic structure such as cyclohexane or cyclopentane,resulting in an α-olefin such as 3-cyclohexyl-1-propene (allylcyclohexane) and vinyl cyclohexane. Although not α-olefins in theclassical sense of the term, for purposes of this invention certaincyclic olefins, such as norbornene and related olefins, particularly5-ethylidene-2-norbornene, are α-olefins and can be used in place ofsome or all of the α-olefins described above. Similarly, styrene and itsrelated olefins (e.g., α-methylstyrene, etc.) are α-olefins for purposesof this invention. Illustrative random polypropylene copolymers includebut are not limited to propylene/ethylene, propylene/1-butene,propylene/1-hexene, propylene/1-octene, and the like. Random copolymerpolypropylenes are commercially available and include DOW randomcopolymer polypropylene resins DS6D82 (MFR=7.0 g/10 min), 6D83K (MFR=1.9g/10 min), C715-12NHP (MFR=12 g/10 min), among others, all availablefrom The Dow Chemical Company.

The term “impact copolymer” refers to heterophasic propylene copolymerswhere polypropylene is the continuous phase (matrix) and an elastomericphase is uniformly dispersed therein. Impact copolymers are a physicalblend of homopolymer with an elastomer, and can be produced bymechanical blending or through the use of multi-stage reactors. Usuallythe impact copolymers are formed in a dual or multi-stage process. Insome embodiments, the impact copolymers have at least 5, at least 6, andpreferably at least 7, up to 35, up to 15, and preferably up to 9, wt %ethylene comonomer. Illustrative impact-modified propylene copolymersinclude those commercially available from The Dow Chemical Company underthe trade designations C766-03 (MFR=3 g/10 min), C7057-07(MFR=7 g/10min), C7061-01N (MFR=1.5 g/10 min), C706-21NA HP (MFR=21 g/10 min).

Thermoplastic Elastomer (TPE). The component “B” thermoplastic elastomer(TPE) is a polyolefin (PO) that (1) has the properties of an elastomerwith the ability to be stretched beyond its original length and retractto substantially its original length when released, and (2) can beprocessed like a thermoplastic with the ability to soften when exposedto heat and return to substantially its original condition when cooledto room temperature. A TPE contains at least two segments, onethermoplastic and the other elastomeric.

The composition can be formulated with one or more TPE resins to enhancethe overall property balance of the composition, which can be present asa dispersed phase within the polyolefin (PO) base resin (matrix), or asa co-continuous phase interspersed with the PO phase, or a TPE as aco-continuous phase with PP and one or more other TPEs dispersedtherein. The TPE(s) can be included at 5 to 80, 10 to 50, 10 to 40, 20to 40 and preferably at 30 to 40, wt % of the composition. Mostpreferred are TPEs having melting temperatures (DSC Tm peak) of greaterthan 130° C., 135° C., 140° C., or 145° C. Nonlimiting examples ofsuitable TPEs according to the invention include styrenic blockcopolymers (e.g., SEBS), propylene-based elastomers/plastomers (e.g.,VERSIFY™ propylene-ethylene copolymers or high melting point VERSIFY™propylene-ethylene copolymers) and olefin block copolymers (OBCs) (e.g.,INFUSE™ 9507 or 9100 OBC).

In general, styrenic block copolymers suitable for the invention includeat least two monoalkenyl arene blocks, preferably two polystyreneblocks, separated by a block of saturated conjugated diene, preferably asaturated polybutadiene block. The preferred styrenic block copolymershave a linear structure, although in some embodiments, branched orradial polymers or functionalized block copolymers make usefulcompounds. The total number average molecular weight of the styrenicblock copolymer is preferably from 30,000 to 250,000 if the copolymerhas a linear structure. Such block copolymers typically have an averagepolystyrene content from 6 to 65, more typically from 10 to 40 wt % ofthe copolymer. Examples of styrenic block copolymers suitable for theinvention are described in EP0712892, WO 2004/041538, U.S. Pat. Nos.6,582,829, 4,789,699, 5,093,422 and 5,332,613, and US 2004/0087235,2004/0122408, 2004/0122409, and 2006/0211819. Nonlimiting examples ofsuitable styrenic block copolymers include styrene/butadiene (SB)copolymers, styrene/ethylene/butadiene/styrene (SEBS) terpolymers,styrene/butadiene/styrene (SBS) terpolymers, hydrogenated SBS or SEBS,styrene/isoprene (SI), and styrene/ethylene/propylene/styrene (SEPS)terpolymers. Commercial sources of styrenic block copolymers includeKraton Polymers (SEBS G1643M, G1651ES), Asahi Kasei ChemicalsCorporation, and Kuraray America.

The terms “polypropylene-based plastomers” (PBP) or “propylene-basedelastomers” (PBE) include reactor grade propylene/α-olefins copolymershaving a heat of fusion <100 J/g and MWD<3.5. The PBPs generally have aheat of fusion <100 J/g while the PBEs generally have a heat of fusion<40 J/g. The PBPs typically have a wt % ethylene in the range of 3 to 15wt %, with the elastomeric PBEs being of 10 to 15 wt % ethylene.

In selected embodiments, the TPE polymer is formed fromethylene/α-olefin copolymers or propylene/α-olefin copolymers. In oneembodiment, the TPE polymer comprises one or more non-polar polyolefins.In one particular embodiment, the TPE polymer is a propylene/α-olefincopolymer, characterized as having substantially isotactic propylenesequences. “Substantially isotactic propylene sequences” means thesequences have an isotactic triad (mm) measured by ¹³C NMRof >0.85, >0.90, >0.92, and, in another alternative, >0.93. Isotactictriads are known in the art and described in, for example, U.S. Pat. No.5,504,172 and WO 2000/01745, which refer to the isotactic sequence interms of a triad unit in the copolymer molecular chain determined by¹³CNMR spectra.

The propylene/α-olefin copolymer may have a melt flow rate (MFR) in therange of from 0.1 to 25 g/10 min., measured in accordance with ASTMD-1238 (at 230° C./2.16 Kg). All individual values and subranges from0.1 to 25 g/10 min. are included and disclosed herein; for example, theMFR can be from a lower limit of 0.1, 0.2, or 0.5, to an upper limit of25, 15, 10, 8, or 5, g/10 min. For example, the propylene/α-olefincopolymer may have a MFR in the range of 0.1 to 10, or in thealternative, 0.2 to 10, g/10 min.

The propylene/α-olefin copolymer has a crystallinity in the range offrom at least 1 to 30 wt % (a heat of fusion of at least 2 to less than50 Joules/gram (J/g)), all individual values and subranges thereof beingincluded and disclosed herein. For example, the crystallinity can befrom a lower limit of 1, 2.5, or 3, wt % (respectively, at least 2, 4,or 5 J/g) to an upper limit of 30, 24, 15 or 7, wt % (respectively, lessthan 50, 40, 24.8 or 11 J/g). For example, the propylene/α-olefincopolymer may have a crystallinity in the range of from at least 1 to24, 15, 7, or 5, wt % (respectively, at least 2 to less than 40, 24.8,11, or 8.3 J/g). Crystallinity is measured via DSC method, as describedabove. The propylene/α-olefin copolymer comprises units derived frompropylene and polymeric units derived from one or more α-olefincomonomers. Exemplary comonomers are C₂, and C₄ to C₁₀ α-olefins; forexample, C₂, C₄, C₆ and C₈ α-olefins.

The propylene/α-olefin copolymer comprises from 1 to 40 wt % of one ormore alpha-olefin comonomers. All individual values and subranges from 1to 40 wt % are included and disclosed herein; for example, the comonomercontent can be from a lower limit of 1, 3, 4, 5, 7 or 9, wt % to anupper limit of 40, 35, 30, 27, 20, 15, 12 or 9, wt %. For example, thepropylene/α-olefin copolymer comprises from 1 to 35 wt %, or, inalternatives, from 1 to 30, 3 to 27, 3 to 20, or from 3 to 15, wt %, ofone or more α-olefin comonomers.

The propylene/α-olefin copolymer has a molecular weight distribution(MWD), defined as weight average molecular weight divided by numberaverage molecular weight (M_(w)/M_(n)) of 3.5 or less; in thealternative 3.0 or less; or in another alternative from 1.8 to 3.0.

Such propylene/α-olefin copolymers are further described in details inU.S. Pat. Nos. 6,960,635 and 6,525,157, incorporated herein byreference. Such propylene/α-olefin copolymers are commercially availablefrom The Dow Chemical Company, under the tradename VERSIFY, or fromExxonMobil Chemical Company, under the tradename VISTAMAXX.

In one embodiment, the propylene/α-olefin copolymers are furthercharacterized as comprising (A) between 60 and less than 100, between 80and 99, and more preferably between 85 and 99, wt % units derived frompropylene, and (B) between greater than zero and 40, preferably between1 and 20, 4 and 16, and even more preferably between 4 and 15, wt %units derived from at least one of ethylene and/or a C₄₋₁₀ α-olefin; andcontaining an average of at least 0.001, at least 0.005 and morepreferably at least 0.01, long chain branches/1000 total carbons,wherein the term long chain branch refers to a chain length of at leastone (1) carbon more than a short chain branch, and wherein short chainbranch refers to a chain length of two (2) carbons less than the numberof carbons in the comonomer. For example, a propylene/1-octeneinterpolymer has backbones with long chain branches of at least seven(7) carbons in length, but these backbones also have short chainbranches of only six (6) carbons in length. The maximum number of longchain branches in the propylene interpolymer is not critical to thedefinition of this embodiment of the instant invention, but typically itdoes not exceed 3 long chain branches/1000 total carbons. Suchpropylene/α-olefin copolymers are further described in U.S. Provisional60/988,999 and PCT/US08/082,599, incorporated herein by reference.

“Olefin block copolymers,” “olefin block interpolymers,” “multi-blockinterpolymers” and like terms refer to a polymer comprising two or morechemically distinct regions or segments (referred to as “blocks”)preferably joined in a linear manner, that is, a polymer comprisingchemically differentiated units which are joined end-to-end with respectto polymerized olefinic, preferable ethylenic, functionality, ratherthan in pendent or grafted fashion. In a preferred embodiment, theblocks differ in the amount or type of incorporated comonomer, density,amount of crystallinity, crystallite size attributable to a polymer ofsuch composition, type or degree of tacticity (isotactic orsyndiotactic), regio-regularity or regio-irregularity, amount ofbranching (including long chain branching or hyper-branching),homogeneity or any other chemical or physical property. Compared toblock interpolymers of the prior art, including interpolymers producedby sequential monomer addition, fluxional catalysts, or anionicpolymerization techniques, the multi-block interpolymers used in thisinvention are characterized by unique distributions of both polymerpolydispersity (PDI or M_(w)/M_(n) or MWD), block length distribution,and/or block number distribution, due, in a preferred embodiment, to theeffect of the shuttling agent(s) in combination with multiple catalystsused in their preparation. More specifically, when produced in acontinuous process, the polymers desirably possess a PDI from 1.7 to3.5, preferably 1.8 to 3, from 1.8 to 2.5, and most preferably from 1.8to 2.2. When produced in a batch or semi-batch process, the polymersdesirably possess a PDI from 1.0 to 3.5, preferably from 1.3 to 3, from1.4 to 2.5, and most preferably from 1.4 to 2.

The term “ethylene multi-block interpolymers” means a multi-blockinterpolymers comprising ethylene and one or more interpolymerizablecomonomers, in which ethylene comprises a plurality of the polymerizedmonomer units of at least one block or segment in the polymer,preferably at least 90, at least 95 and most preferably at least 98,mole % of the block. Based on total polymer weight, the ethylenemulti-block interpolymers used in the practice of the present inventionpreferably have an ethylene content of 25 to 97, of 40 to 96, of 55 to95, and most preferably of 65 to 85, %.

Because the respective distinguishable segments or blocks formed fromtwo of more monomers are joined into single polymer chains, the polymercannot be completely fractionated using standard selective extractiontechniques. For example, polymers containing regions that are relativelycrystalline (high density segments) and regions that are relativelyamorphous (lower density segments) cannot be selectively extracted orfractionated using differing solvents. In a preferred embodiment thequantity of extractable polymer using either a dialkyl ether or analkane-solvent is <10, <7, <5 and most preferably <2, % of the totalpolymer weight.

In addition, the multi-block interpolymers used in the practice of theinvention desirably possess a PDI fitting a Schutz-Flory distributionrather than a Poisson distribution. The use of the polymerizationprocess described in WO 2005/090427 and U.S. Ser. No. 11/376,835 resultsin a product having both a polydisperse block distribution as well as apolydisperse distribution of block sizes. This results in the formationof polymer products having improved and distinguishable physicalproperties. The theoretical benefits of a polydisperse blockdistribution have been previously modeled and discussed in Potemkin,Physical Review E (1998) 57 (6), pp. 6902-6912, and Dobrynin, J. Chem.Phvs. (1997) 107 (21), pp 9234-9238.

In a further embodiment, the multi-block interpolymers, especially thosemade in a continuous, solution polymerization reactor, possess a mostprobable distribution of block lengths. In an embodiment of thisinvention, the ethylene multi-block interpolymers are defined as having:

(A) M_(w)/M_(n) from about 1.7 to about 3.5, at least one melting point,T_(m), in degrees Celsius, and a density, d, in grams/cubic centimeter,where in the numerical values of T_(m) and d correspond to therelationship: T_(m)>−2002.9+4538.5(d)−2422.2(d)², or

(B) M_(w)/M_(n) from about 1.7 to about 3.5, and is characterized by aheat of fusion,)H in J/g, and a delta quantity,)T, in degrees Celsiusdefined as the temperature difference between the tallest DSC peak andthe tallest CRYSTAF peak, wherein the numerical values of)T and)H havethe following relationships:)T>−0.12990( )H)+62.81 for)H greater thanzero and up to 130 J/g, and)T≧48C for)H greater than 130 J/g, whereinthe CRYSTAF peak is determined using at least 5% of the cumulativepolymer, and if less than 5% of the polymer has an identifiable CRYSTAFpeak, then the CRYSTAF temperature is 30° C.; or

(C) Elastic recovery, Re, in % at 300% strain and 1 cycle measured witha compression-molded film of the ethylene/α-olefin interpolymer, and hasa density, d, in g/cc, wherein the numerical values of Re and d satisfythe following relationship when ethylene/α-olefin interpolymer issubstantially free of crosslinked phase: Re>1481-1629(d); or

(D) A molecular weight fraction which elutes between 40° C. and 130° C.when fractionated using TREF, characterized in that the fraction has amolar comonomer content of at least 5% higher than that of a comparablerandom ethylene interpolymer fraction eluting between the sametemperatures, wherein said comparable random ethylene interpolymer hasthe same comonomer(s) and has a melt index, density and molar comonomercontent (based on the whole polymer) within 10% of that of theethylene/α-olefin interpolymer; or

(E) A storage modulus at 25° C., G′(25° C.), and a storage modulus at100° C., G′(100° C.), wherein the ratio of G′(25° C.) to G′(100° C.) isin the range of about 1:1 to about 9:1.

The ethylene/α-olefin multi-block interpolymer may also have:

(F) A molecular fraction which elutes between 40° C. and 130° C. whenfractionated using TREF, characterized in that the fraction has a blockindex of at least 0.5 and up to about 1 and a molecular weightdistribution, M_(w)/M_(n) greater than about 1.3; or

(G) An average block index greater than zero and up to about 1.0 and amolecular weight distribution, M_(w)/M_(n) greater than about 1.3.

Suitable monomers for use in preparing the ethylene multi-blockinterpolymers used in this invention include ethylene and one or moreaddition polymerizable monomers other than ethylene. Examples ofsuitable comonomers include straight-chain or branched α-olefins of 3 to30, preferably 3 to 20, carbon atoms, such as propylene, 1-butene,1-pentene, 3-methyl-1-butene, 1-hexene, 4-methyl-1-pentene,3-methyl-1-pentene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene,1-hexadecene, 1-octadecene and 1-eicosene; cyclo-olefins of 3 to 30,preferably 3 to 20, carbon atoms, such as cyclopentene, cycloheptene,norbornene, 5-methyl-2-norbornene, tetracyclododecene, and2-methyl-1,4,5,8-dimethano-1,2,3,4,4a,5,8,8a-octahydronaphthalene; di-and polyolefins, such as butadiene, isoprene, 4-methyl-1,3-pentadiene,1,3-pentadiene, 1,4-pentadiene, 1,5-hexadiene, 1,4-hexadiene,1,3-hexadiene, 1,3-octadiene, 1,4-octadiene, 1,5-octadiene,1,6-octadiene, 1,7-octadiene, ethylidenenorbornene, vinyl norbornene,dicyclopentadiene, 7-methyl-1,6-octadiene,4-ethylidene-8-methyl-1,7-nonadiene, and 5,9-dimethyl-1,4,8-decatriene;and 3-phenylpropene, 4-phenylpropene, 1,2-difluoroethylene,tetrafluoroethylene, and 3,3,3-trifluoro-1-propene.

Other ethylene multi-block interpolymers that can be used in thisinvention are elastomeric interpolymers of ethylene, a C₃₋₂₀ α-olefin,especially propylene, and, optionally, one or more diene monomers.Preferred α-olefins for use in this embodiment are designated by theformula CH₂═CHR*, where R* is a linear or branched alkyl group of from 1to 12 carbon atoms. Examples of suitable α-olefins include, but are notlimited to, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene,4-methyl-1-pentene, and 1-octene. One particularly preferred α-olefin ispropylene. The propylene based polymers are generally referred to in theart as EP or EPDM polymers. Suitable dienes for use in preparing suchpolymers, especially multi-block EPDM type-polymers include conjugatedor non-conjugated, straight or branched chain-, cyclic- or polycyclicdienes containing from 4 to 20 carbon atoms. Preferred dienes include1,4-pentadiene, 1,4-hexadiene, 5-ethylidene-2-norbornene,dicyclopentadiene, cyclohexadiene, and 5-butylidene-2-norbornene. Oneparticularly preferred diene is 5-ethylidene-2-norbornene.

Because the diene containing polymers contain alternating segments orblocks containing greater or lesser quantities of the diene (includingnone) and α-olefin (including none), the total quantity of diene andα-olefin may be reduced without loss of subsequent polymer properties.That is, because the diene and α-olefin monomers are preferentiallyincorporated into one type of block of the polymer rather than uniformlyor randomly throughout the polymer, they are more efficiently utilizedand subsequently the crosslink density of the polymer can be bettercontrolled. Such crosslinkable elastomers and the cured products haveadvantaged properties, including higher tensile strength and betterelastic recovery.

The ethylene multi-block interpolymers useful in the practice of thisinvention have a density of less than 0.90, preferably less than 0.89,less than 0.885, less than 0.88 and even more preferably less than0.875, g/cc. The ethylene multi-block interpolymers typically have adensity greater than 0.85, and more preferably greater than 0.86, g/cc.Density is measured by the procedure of ASTM D-792. Low density ethylenemulti-block interpolymers are generally characterized as amorphous,flexible and having good optical properties, e.g., high transmission ofvisible and UV-light and low haze. The ethylene multi-blockinterpolymers useful in this invention typically have a MFR of 1-10 g/10min. as measured by ASTM D1238 (190° C./2.16 kg). The ethylenemulti-block interpolymers useful in the practice of this invention havea 2% secant modulus of <150, preferably <140, <120 and even morepreferably <100, mPa as measured by the procedure of ASTM D-882-02. Theethylene multi-block interpolymers typically have a 2% secant modulus ofgreater than zero, but the lower the modulus the better the interpolymeris adapted for use in this invention. The secant modulus is the slope ofa line from the origin of a stress-strain diagram and intersecting thecurve at a point of interest, and it is used to describe the stiffnessof a material in the inelastic region of the diagram. Low modulusethylene multi-block interpolymers are particularly well adapted for usein this invention because they provide stability under stress, e.g.,less prone to crack upon stress or shrinkage. The ethylene multi-blockinterpolymers useful in this invention typically have a melting point ofless than about 125° C. The melting point is measured by thedifferential scanning calorimetry (DSC) method described in WO2005/090427 (US 2006/0199930). Ethylene multi-block interpolymers with alow melting point often exhibit desirable flexibility andthermoplasticity properties useful in the fabrication of the wire andcable sheathings of this invention. The ethylene multi-blockinterpolymers used in the practice of this invention, and theirpreparation and use, are more fully described in U.S. Pat. Nos.7,579,408, 7,355,089, 7,524,911, 7,514,517, 7,582,716 and 7,504,347.

Olefinic block copolymers useful in the practice of this inventioninclude INFUSE® OBCs, available from The Dow Chemical Company), e.g.,INFUSE OBC D9100 (1MI, 0.877, 74A Shore), D9500 (5MI, 0.877, 74A Shore),D9507 or D9530 (5MI, 0.887, 85A Shore).

Other TPE Polymers. Other TPE polymers include, for example, but are notlimited to, thermoplastic urethane (TPU), ethylene/vinyl acetate (EVA)copolymers (e.g., Elvax 40L-03 (40% VA, 3MI) (DuPont)), ethylene/ethylacrylate (EEA) copolymers (e.g., AMPLIFY) and ethylene acrylic acid(EAA) copolymers (e.g., PRIMACOR) (The Dow Chemical Company),polyvinylchloride (PVC), epoxy resins, styrene acrylonitrile (SAN)rubber, and Noryl® modified PPE resin (amorphous blend of polyphenyleneoxide (PPO) and polystyrene (PS) by SABIC), among others. Also usefulare olefinic elastomers including, for example, very low densitypolyethylene (VLDPE) (e.g., FLEXOMER® ethylene/1-hexene polyethylene,The Dow Chemical Company), homogeneously branched, linearethylene/α-olefin copolymers (e.g. TAFMER® by Mitsui PetrochemicalsCompany Limited and EXACT® by DEXPlastomers), and homogeneouslybranched, substantially linear ethylene/α-olefin polymers (e.g.,AFFINITY® ethylene-octene plastomers (e.g., EG8200 (PE)) and ENGAGE®polyolefin elastomers, The Dow Chemical Company). Substantially linearethylene copolymers are more fully described in U.S. Pat. Nos.5,272,236, 5,278,272 and 5,986,028. Additional olefinic interpolymersuseful in the present invention include heterogeneously branchedethylene-based interpolymers including, but are not limited to, linearmedium density polyethylene (LMDPE), linear low density polyethylene(LLDPE), and ultra low density polyethylene (ULDPE). Commercial polymersinclude DOWLEX™ polymers, ATTANE™ polymer, FLEXOMERT™, HPDE 3364 andHPDE 8007 polymers (The Dow Chemical Company), ESCORENE™ and EXCEED™polymers (Exxon Mobil Chemical). Nonlimiting examples of suitable TPUsinclude PELLETHANE™ elastomers (Lubrizol Corp. (e.g., TPU 2103-90A);ESTANE™, TECOFLEX™, CARBOTHANE™, TECOPHILIC™, TECOPLAST™ and TECOTHANE™(Noveon); ELASTOLLAN™, etc. (BASF), and commercial TPUs available fromBayer, Huntsman, the Lubrizol Corporation and Merquinsa.

The ethylene interpolymers useful in the present invention includeethylene/α-olefin interpolymers having a α-olefin content typically ofat least 5, more typically at least 15 and even more typically of atleast about 20, wt % based on the weight of the interpolymer. Theseinterpolymers typically have an α-olefin content of <90, more typically<75 and even more typically <50, wt % based on the weight of theinterpolymer. The α-olefin content is measured by ¹³C nuclear magneticresonance (NMR) spectroscopy using the procedure described in Randall(Rev. Macromol. Chem. Phys., C29 (2&3)). The α-olefin is preferably aC₃₋₂₀ linear, branched or cyclic α-olefin, for example, propene,1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene,1-tetradecene, 1-hexadecene, and 1-octadecene. The α-olefins also cancontain a cyclic structure such as cyclohexane or cyclopentane,resulting in an α-olefin such as 3-cyclohexyl-1-propene (allylcyclohexane) and vinyl cyclohexane. Although not α-olefins in theclassical sense of the term, for purposes of this invention certaincyclic olefins, such as norbornene and related olefins, particularly5-ethylidene-2-norbornene, are α-olefins and can be used in place ofsome or all of the α-olefins described above. Similarly, styrene and itsrelated olefins (for example, α-methylstyrene, etc.) are α-olefins forpurposes of this invention. Illustrative polyolefin copolymers includeethylene/propylene, ethylene/butene, ethylene/1-hexene,ethylene/1-octene, ethylene/styrene, and the like. Illustrativeterpolymers include ethylene/propylene/1-octene,ethylene/propylene/butene, ethylene/butene/1-octene,ethylene/propylene/diene monomer (EPDM) and ethylene/butene/styrene. Thecopolymers can be random or blocky.

Flame Retardant (FR) System. In an embodiment the component “C” flameretardant (FR) system used in the practice of this invention comprisesone or more organic phosphorus-based and/or nitrogen-based intumescentFR, including a piperazine component. The preferred amount of thenitrogen/phosphorus-based FR used in the compositions of this inventionis at least 1, 10, 15, 20 and most preferably at least 30 wt %, based onthe weight of the composition. The typical maximum amount of the organicnitrogen/phosphorus-based FR does not exceed 70, 60, 50, and morepreferably does not exceed 45, wt % of the composition.

In an embodiment the component “C” flame retardant (FR) system used inthe practice of this invention comprises 1-99 wt % piperazine based FRand 1-99 wt % other flame retardant, based on the total weight of the FRsystem. The preferred amount of the piperazine based FR is at least 5,10, 20, 30, 40, and at least 50, wt %. In particular embodiments, the FRsystem can comprise 55-65 wt % piperazine based FR and 35-45 wt % otherflame retardant (e.g., non-metal salts of phosphoric acid).

Organic nitrogen and/or phosphorus-based intumescent FRs include, butare not limited to, organic phosphonic acids, phosphonates,phosphinates, phosphonites, phosphinites, phosphine oxides, phosphines,phosphites or phosphates, phosphonitrilic chloride, phosphorus esteramides, phosphoric acid amides, phosphonic acid amides, phosphinic acidamides, and melamine and melamine derivatives, including melaminepolyphosphate, melamine pyrophosphate and melamine cyanurate, andmixtures of two or more of these materials. Examples includephenylbisdodecyl phosphate, phenylbisneopentyl phosphate, phenylethylene hydrogen phosphate, phenyl-bis-3,5,5′-trimethylhexylphosphate), ethyldiphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate,diphenyl hydrogen phosphate, bis(2-ethyl-hexyl) p-tolylphosphate,tritolyl phosphate, bis(2-ethylhexyl)-phenyl phosphate, tri(nonylphenyl)phosphate, phenylmethyl hydrogen phosphate, di(dodecyl) p-tolylphosphate, tricresyl phosphate, triphenyl phosphate, triphenylphosphate, dibutylphenyl phosphate, 2-chloroethyldiphenyl phosphate,p-tolyl bis(2,5,5′-trimethylhexyl) phosphate, 2-ethylhexyldiphenylphosphate, and diphenyl hydrogen phosphate. Phosphoric acid esters ofthe type described in U.S. Pat. No. 6,404,971 are examples ofphosphorus-based FRs. Additional examples include liquid phosphates suchas bisphenol A diphosphate (BAPP) (Adeka Palmarole) and/or resorcinolbis(diphenyl phosphate) (Fyroflex RDP) (Supresta, ICI), and solidphosphorus such as ammonium polyphosphate (APP), piperazinepyrophosphate, piperazine orthophosphate and piperazine polyphosphate.APP is often used with flame retardant co-additives, such as melaminederivatives. Also useful is Melafine (DSM)(2,4,6-triamino-1,3,5-triazine; fine grind melamine).

Examples of piperazine components of the FR system include compoundssuch as piperazine pyrophosphate, piperazine orthophosphate andpiperazine polyphosphate. Additional examples include polytriazinylcompounds or oligomer or polymer 1,3,5-triazine derivatives including apiperazine group, as described in US 2009/0281215 and WO 2009/016129,the disclosures of which are incorporated by reference herein.

Embodiments of the FR system comprise one or more non-metal salts ofphosphoric acid, for example but not limited to, APP, melamine and/or amelamine derivative such as melamine pyrophosphate and melaminepolyphosphate, and one or more piperazine components, for example butnot limited to, a piperazine compound such as piperazine pyrophosphate,piperazine orthophosphate, piperazine polyphosphate, a polytriazinylcompound comprising a piperazine group, etc., and/or a oligomer orpolymer 1,3,5-triazine derivative comprising a piperazine group. Inparticular embodiments, the FR system is a blend of APP, melamine and/ora melamine derivative, and a piperazine compound such as piperazinepyrophosphate, piperazine orthophosphate, and/or piperazinepolyphosphate. In another embodiment, the FR system is a blend of APP,melamine and/or a melamine derivative and an oligomer or polymer1,3,5-triazine derivative comprising a piperazine group. In someembodiments, the FR material comprises a melamine-based coating. Suchorganic nitrogen/phosphorus-based intumescent material blends arecommercially available as FP-2200 and FP-2100J, intumescent flameretardants from Amfine Chemical Corporation (USA) (Adeka Palmarole SAS),PNP1D available from JLS Chemical (China), and as Budit 3167 availablefrom Budenheim Ibérica Comercial, S.A. (Spain).

The PP/TPE/intumescent FR blends of this invention, in particular blendswith FP2100J, PNP1D and/or Budit 3167 as a primary FR chemical, exhibitexcellent burn performance and resulted in a synergistic balance ofsuperior flame retardancy sufficient to pass the VW-1 testingrequirements (UL 1581) and tensile properties including a tensile stresslarger than 8 MegaPascals (MPa) and a tensile elongation larger than200% (ASTM D638), a heat deformation ratio <50% at 150° C.(UL1581-2001), and good flexibility and softness (2% Secant modulus <250MPa (ASTM D638); Shore A hardness of <95 (ASTM D2240).

Optional Additive Package. Component “D” additional additives can beincluded in a range of 0.1 to 20 wt % of the composition. The PP/TPE/FRcompositions can incorporate one or more stabilizers and/or additivesfound useful for PP/TPE applications such as, but not limited to,antioxidants (e.g., hindered phenols such as IRGANOX™ 1010 (Ciba/BASF)),thermal (melt processing) stabilizers, hydrolytic stability enhancers,heat stabilizers, acid scavengers, colorants or pigments, UVstabilizers, UV absorbers, nucleating agents, processing aids (such asoils, organic acids such as stearic acid, metal salts of organic acids),antistatic agents, smoke suppressants, anti-dripping agents, tougheners,plasticizers (such as dioctylphthalate or epoxidized soy bean oil),lubricants, emulsifiers, optical brighteners, coupling agents, silanes(in free form or as filler surface modifier), cement, urea, polyalcoholslike pentaerythritol, minerals, peroxides, light stabilizers (such ashindered amines), mold release agents, waxes (such as polyethylenewaxes), viscosity modifiers, charring agents (e.g., pentaerythritol),and other additives, to the extent that these additives do not interferewith the desired physical or mechanical properties of the articles madefrom the compositions of the present invention. These additives are usedin known amounts and in known ways, but typically the additive packagecomprises, if present at all, greater than zero, e.g., 0.01, to 2, moretypically 0.1 to 1, wt % of the final composition. Examples of usefulviscosity modifiers include polyether polyols such as Voranol 3010 andVoranol 222-029, available from The Dow Chemical Company). Usefulcommercially available anti-dripping agents include triglycidylisocyanurate (TGIC), VIKOFLEX 7010 (methyl epoxy soyate (epoxidizedester family)), and VIKOLOX alpha olefin epoxy (C-16) (mixture of1,2-epoxyhexadecane (>95 wt %) and 1-hexadecene (<5 wt %), bothavailable from eFAME. A useful dispersant/metal chelater isn-octylphosphonic Acid (UNIPLEX OPA).

In preferred embodiments, the compositions of the invention do notinclude a functionalized compatibilizer or modifier such as a maleicacid anhydride olefin-based polymer or polyolefin (e.g., PE-g-MAH,EVA-g-MAH, etc). The present compositions can include acompatibilizer/coupling agent such as ethylene vinyl acetate (EVA)copolymer (e.g., ELVAX 40L-03 (40% VA, 3MI) by DuPont), aminated OBCs(e.g., INFUSE 9807 by The Dow Chemical Company). Examples of othercoupling agents include polysiloxane containing vinyl and ethoxy groups(e.g., Dynasylan 6498 (oligomeric vinyl silane)) and hydroxy-terminateddimethylsiloxane (<0.1 vinyl acetate).

In some applications, the FR system can optionally include minor amounts(less than 5, preferably less than 2, wt % of the composition) ofinorganic, non-halogenated flame retardants (fillers) and synergists incombination with the FR system. Inorganic, non-halogenated FR fillersinclude, for example, metal hydrates such as aluminum hydrate andmagnesium hydrate, metal hydroxides such as magnesium hydroxide(Mg(OH)₂) and aluminum trihydroxide (ATH) (e.g., Apyral 40CD (Nabeltec))metal oxides such as titanium dioxide, silica, alumina, huntite,antimony trioxide, potassium oxide, zirconium oxide, zinc oxide andmagnesium oxide, carbon black, carbon fibers, expanded graphite, talc,clay, organo-modified clay, calcium carbonate, red phosphorous,wollastonite, mica, ammonium octamolybdate, fits, hollow glassmicrospheres, glass fibers, expanded graphite and the like.

In preferred embodiments, the compositions of the invention do notinclude silicone oil (polydimethylsiloxane), although in certainapplications, a minor amount (<5, preferably <2, wt % of thecomposition) of silicone oil can be included as a process aid and flameretardant booster. In preferred embodiments, the compositions of theinvention are not blended or diluted with other polymers such aspolyolefin-rubber elastomers, olefine-octene or olefin-alkyl acrylatecopolymer-based elastomers, functionalized polymers (e.g., containing acarboxylic acid or acid anhydride group), anhydride-modifiedolefin-based polymers/polyolefins, or polyolefin elastomers grafted withpolar groups. However, in some embodiments, the propylene and TPE can beblended or diluted with one or more other polymers to adjust propertyand extrusion performance balance, to the extent that, in a preferredmode, the propylene component “A” constitutes at least 5, at least 10,and more preferably at least 20, and the TPE component “B” constitutesat least 5, at least 10, and more preferably at least 20, wt % of thecomposition.

Relative Amounts of PP, TPE and FR. The propylene polymer (PP) andthermoplastic elastomer (TPE) are blended with one another in anyconvenient manner to form a polymer matrix, for example, PP as acontinuous phase and the TPE component as a discontinuous or dispersedphase, or PP with one or more TPEs as a co-continuous phase and one ormore other TPEs as a discontinuous or dispersed phase. Blends of any ofthe propylenes or TPEs can be used in this invention. The relativeamounts of propylene polymer (PP), TPE and FR in the composition canvary widely, but typically, the PP comprises 5-80, 10-60, 10-40, 20-40,and more preferably greater than 20 to less than or equal to 30; the TPEcomprises 5-80, 10-50, 10-40, 20-40 and preferably 30-40; and the FRcomprises 10 to 70, 15 to 50, and more typically 30 to 45, wt % of thecomposition.

The compositions of the invention combine PP, TPE (e.g., styrenic blockcopolymers, olefin-based TPEs, OBCs, etc.) and an intumescent N—P flameretardant (FR) system comprising a piperazine component (e.g., AdekaFP2100J), to formulate an HFFR package. In embodiments, the inventionprovides a PP/TPE-based HFFR that utilizes a polyolefin or thermoplasticelastomer alone and, surprisingly this combination together with thedescribed organic N—P based intumescent FR system, in particularFP2100J, PNP1D and/or Budit 3167, comprising a piperazine component,exhibits a burn synergistic effect, exceptional flame retardancy, and atthe same time, affords good mechanical properties and excellent heatdeformation performance as high as 150° C. In a particular embodiment,the composition comprises a HFFR blend of PP with a TPE such as VERSIFY™or high melting point VERSIFY™ polypropylene/ethylene copolymer and anN—P-based intumescent FR system comprising a piperazine component (e.g.,FP2100J, PNP1D or Budit 3167) for W&C applications.

Compounding/Fabrication. Compounding of the compositions of thisinvention can be performed by standard means known to those skilled inthe art. Examples of compounding equipment are internal batch mixers,e.g., Banbury or Bolling internal mixer. Alternatively, continuoussingle or twin screw mixers can be used, e.g., Farrel continuous mixer,Werner and Pfleiderer twin screw mixer, or Buss kneading continuousextruder. The type of mixer utilized, and the operating conditions ofthe mixer, will affect properties of the composition such as viscosity,volume resistivity, and extruded surface smoothness. The compoundingtemperature of the PP/TPE polymer blend with the FR and optionaladditive packages is typically from 120 to 220° C., more typically from160 to 200° C. The various components of the final composition can beadded to and compounded with one another in any order, orsimultaneously, but typically a compatibilizers (if included) is firstcompounded with the PP and the TPE is first compounded with one or moreof the components of the FR package, and the two mixtures with anyremaining components of the FR package and any additives are compoundedwith one another. In some embodiments, the additives are added as apre-mixed masterbatch, which are commonly formed by dispersing theadditives, either separately or together, into an inert plastic resin,e.g., one of the plastic matrix components or a low densitypolyethylene. Masterbatches are conveniently formed by melt compoundingmethods.

Articles of Manufacture. In particular embodiments, the polymercomposition can be applied as a covering to a cable, e.g., a sheath,jacket or insulation layer, in known amounts and by known methods (e.g.,with equipment and methods described in U.S. Pat. Nos. 5,246,783 and4,144,202). Typically, the composition is prepared in a reactor-extruderequipped with a cable-coating die and after the components areformulated, the composition is extruded over the cable as the cable isdrawn through the die. The sheath is then typically subjected to a cureperiod at temperatures from ambient up to but below the melting point ofthe composition until the article has reached the desired degree ofcrosslinking. Cure may begin in the reactor-extruder.

The compositions of the invention can be used in a broad range ofnon-halogen or halogen-free FR applications requiring high flameretardancy and good flexibility, PVC replacement use, etc. for both W&Cand other market segments, and are particularly well suited forapplications requiring high flexibility and/or high burn resistance, incombination with good wet insulation resistance. Non-limiting examplesof articles of manufacture that can be prepared from the compositions ofthis invention include AC plug and SR connectors, wire insulations/cablejackets, watch straps, handles, grips, soft touch articles and buttons,weather-stripping, automotive applications including glass run channelseals, interior panels, seals, gaskets, window seals and extrudedprofiles, consumer electronic applications, and low voltageapplications, among others. These articles can be manufactured usingknown equipment and techniques.

The invention is described more fully through the following examples.Unless otherwise noted, all parts and percentages are by weight.

Specific Embodiments

Materials. The following materials are used in the following examples.The materials are dried or otherwise treated, if at all, as described.MFR at dg/min (ASTM D-1238; 2.16 kg @ 230° C. unless designatedotherwise). Density (d) at g/cm³ (ASTM D-792).

PP (6D83K) ¹ polypropylene random copolymer (MFR = 1.9) PP (C715-12) ¹polypropylene random copolymer (MFR = 12) PP (H110-02N) ¹ polypropylenerandom copolymer (MFR = 2) DOW DS6D82 ¹ random polypropylene (MFR = 7)INSPIRE 117 ¹ polypropylene impact copolymer (MFR = 2.1) SEBS (G1643M) ²styrene-ethylene-butylene-styrene (MFR = 18 (5 kg @ 200° C.); d = 0.9)VERSIFY ¹ propylene-ethylene copolymer VERSIFY 2300 (MFR = 2; d = 0.867)VERSIFY 3300 (MFR =8; d = 0.867) VERSIFY 2400 (MFR = 2; d = 0.858)VERSIFY 4200 (MFR = 25; d = 0.876) VERSIFY 3000 (MFR = 8; d = 0.891)VERSIFY 4301 (MFR = 25; d = 0.868) VERSIFY 3200 (MFR = 8; d = 0.876)VERSIFY 2400.05 (MFR = 2; d = 0.863) INFUSE D9530 OBC (MFR = 5 (2.16 kg@ 190° C.); d = 0.887, 74A Shore). Before use, samples dried at 47° C.for at least 6 hrs under vacuum. FP-2100J ³ N/P-based intumescent FRwith piperazine pyrophosphate FR CROS C30 ⁴ intumescent FR (coated APP(>98 wt %) and melamine (<2 wt %) Budit 311 ⁴ di-melamine pyrophosphate(MPP) intumescent FR Budit 3141 ⁴ melamine polyphosphate (MPP)intumescent FR Budit 3167 ⁴ intumescent FR filler (APP/piperazinecomponent/melamine coating) Reofos BAPP ⁵ intumescent FR fluid(phosphoric trichloride reaction product with bisphenol A and phenol +triphenyl phosphate) DC-200 Fluid 60M ⁶ silicone oil (60K cSt)-polydimethylsiloxane process aid/FR booster Irganox 1010 ⁷ phenolicbased anti-oxidant (tetrakis(methylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate))methane). Irgafos 168 ⁷ Trisarylphosphite processingstabilizer Elvax ® (EVA265)⁸ ethylvinyl acetate JLS PNP1D⁹ aluminumpolyphosphate based flame retardant Melamine⁹1,3,5-triazine-2,4,6-triamine PER¹⁰ pentaerythritol ZnO¹⁰ zinc oxide ¹The Dow Chemical Company ² Kraton ³ Adeka Palmarole ⁴ Budenheim ⁵Chemtura Corporation ⁶ Dow Corning Corp. ⁷ Ciba/BASF ⁸DuPont ⁹JLS FlameRetardants ¹⁰Sinopharm Chemical Reagent Col., Ltd.

Melt Mixing/Melt Compounding. Resin batches were prepared using a CWBrabender model Prep-Mixer®/Measuring Head laboratory electric batchmixer equipped with Cam Blades, a large mixer/measuring head, 3-piecedesign with two heating zones and 350/420 ml capacity dependent on mixerblade configuration. Net chamber volume with Cam Blades inserted is 420ml and batch size can be corrected for composition density to provideproper fill of the mixing bowl using the following calculation: Batchweight=calculated SG* (500/1.58) (formula ‘a’). The empiricalrelationship was based on relatively good mixing at a batch weight ofabout 500 g at a 75% fill factor with SG about 1.58. At a constant mixervolume, batch weight is adjusted with a change in SG of each batch forgood mixing. V=mass/density; when V is constant, M₁/D₁=M₂/D₂ orM₂=M₁D₂/D₁. For the compositions in this study, this provided batchsizes of about 360 to 400 g. The design of the Cam Blades as a mediumshear-rate blade imposed milling, mixing and shearing forces against thetest sample, alternating compacting and releasing the material withinthe chamber. The gear offset of the mixer was a 3:2 drive blade todriven blade gear ratio (for every three rotations of the drive blade,two rotations of the driven blade), with the drive blade being powereddirectly by the drive motor and the driven blade rotating on the gearingbuilt into the mixing bowl.

First, the base resins were added into the mixing bowl with the bladesrotating at 15 rpm. The process temperature set point for both zones was170 or 180° C. depending on the melt temperature of the compound. Therotor speed was then increased to 40 rpm until full fluxing was reached.The mixing speed was reduced to 20 rpm to add the remaining ingredients(i.e., antioxidants, other liquid components). Once the additives wereloaded, the ram arm closure assembly was lowered and mixing speed wasincreased to 40 rpm. Duration of the mixing cycle was 3 min. Whencompleted, the molten material was backed out of the mixer usingtweezers, collected, placed between two Mylar sheets, and compressionmolded at room temperature into a flat pancake. The cooled sample wascut into small squares and strips for plaque preparation and granulationusing a #3 Armature Greenerd Arbour press and large cutting knife.Additional compounding was also carried out using Haake mixers. Themixing steps or compound step is as follows. First, the PP and TPE witha certain ratio were fed into a Haake mixer at 190° C. (about 3 min.) tomelt the polymer. The FR (FP2100J) was added and mixed for another 3min. to a homogenous blend. The mixture was removed, cooled to roomtemperature, and compression molded via a molder, Haoli XLB-D350*350*1(Changzhou No. 1 Plastic and Rubber Equipment Ltd. Co.), according tothe requirements of each of the test methods below.

Plaque Preparation. Samples were compression molded using a GreenardHydrolair steam press (with quench cooling capability) operated in themanual mode. One 8×8 50-mil plaque for each sample was prepared. Thepress was preheated to 180° C. (±5° C.). A total of 85 g of material waspre-weighed and placed in the center of a 50-mil stainless steel plaquebetween the mold assembly made up of mold release treated Mylar andaluminum sheets. The filled mold was then placed into the press at 500psi for 3 min., and the pressure was increased to 2,200 psi for 3 min.Steam/water switching occurred 15 seconds prior to the 3-min. mark andthe sample was quench-cooled for 5 min. at the high pressure setting.

Granulation. Samples were granulated using a Thomas-Whiley ED Model4-knife mill (grinding chamber with rotor with 4 adjustable cuttingblades operating edge against edge with 4 stationary blades; gap sizebetween the stationery and adjustable blades set to 0.030-inch;operating speed of rotating head set at 1,200 rpm; 6-mm screen).Granulated material was collected in a product receiver at the base ofthe instrument, for extrusion or plaque preparation.

Material Drying. Before lab extrusion or specimen preparation,granulated material was vacuum dried (at least 6 hrs at 85° C., highvacuum (<2.0″ Hg)) to remove free moisture that might cause porosity ormaterial degradation, enclosed in a foil bag and cooled to roomtemperature prior to the lab extrusion work.

Brabender Tape Extruder. A 3-barrel zone, 25:1 L/D, ¾″ Brabenderextruder with 1″×0.020″ “coat hanger slit” type tape die was used with a3:1 compression ratio metering screw. No breaker plate or screen packwas used. Zone temperatures were set at 170, 175, 180, and 180, ° C.from feed throat to die, respectively. Vacuum dried tape samples wereextruded with a screw speed starting at 20 rpm and about 6 meters oftape samples were collected on a moving Teflon-coated conveyor belt(about 1 m bed length and 1 m/min. speed capacity). Screw and conveyorbelt speeds were adjusted for a tape thickness of about 0.018″ (0.457mm).

Tensile Test Samples. Extruded tape samples were conditioned for 40hours (controlled environment) at 73.4° F. (+/−6° F.) with 50% (+/−5%)relative humidity (RH), and then cut with an arbor press and anASTM-D638 Type IV tensile bar die (providing 4.5″) overall dogbonespecimen length (11.43 cm) with 0.250° wide test zone (7.62 cm)).

Mini Wire Line. A 3-barrel zone, 25:1 L/D, ¾″ Brabender extruder (0.050″tip (1.27 mm); 0.080 die) was used with a 3:1 compression ratio meteringscrew. No breaker plate or screen pack was used. The bare copperconductor was 18 AWG/41 strands with nominal diameter of 0.046 inches(1.168 mm). Zone temperatures were set at 180° C. for all zonesincluding the die. Wire coated samples were cooled in a water trough 4to 5 inches (10-13 cm) from the die. Vacuum-dried samples were extrudedat a screw speed of 25 to 30 rpm, adjusted for a 0.085″ (2.16 mm or 85mils) target diameter for about 0.020″ (20 mils) wire coating thickness.A minimum 60 feet (18 m) of wire-coated samples were collected on amoving conveyor belt (speed at 15 feet/min. (4.57 m/min.)).

Tensile Testing. Tensile testing was conducted on a INSTRON Renew 420165/16 and 4202 65/16 apparatus using a special 2-speed protocol toprovide secant modulus followed by tensile and elongation at breakmeasurements. Tensile tests are carried out according to ASTM D638 atroom temperature. A time-based displacement method is used to determinethe secant modulus strain levels to eliminate difficulties withextensometer slippage and poor resolution at low extension levels usedfor the modulus test. For the ASTM Type IV dogbone used, strain isassumed to occur over a 2.0″ effective length (50 mm). Therefore, a 1%strain increment corresponds to a 0.50-mm jaw movement and, at 50 mm/mintest speed, equals 0.010 min (0.6 sec.). To eliminate “start-up” noiseand pre-tension the specimen, the secant modulus with a “starting load”was calculated at 0.4 seconds, with 1% load measurements at 1 sec., 2%load at 1.6 sec., and 5% load at 3.4 sec. The 1% secant load equals the1-sec. load minus the 0.4-sec. load; the 2% secant load equals the1.6-sec. load minus the 0.4-sec. load, etc. This load is used in thestandard secant modulus calculation; e.g., 2% secant modulus=(2% secantload) measured specimen cross-sectional area). At 18 sec. (30%elongation), the testing speed automatically increased to 500 mm/min.then completed the tensile to break portion of the testing. Standarddeviation for 5 repeat specimens on 1% secant modulus is typically <5%of average value using the time-based strain method, versus the standarddeviation often above 25% of average value with the priorextensometer-based strain method. Since the INSTRON program for thistesting is based on 2.0″ (50 mm) effective strain length (Type IVdogbone), values were calculated for each test run.

Heat Deformation/Wire. This test is used to establish the resistance todeformation of wire or cable insulation or jacket at elevatedtemperatures. The apparatus consists of a forced-circulation air oven,temperature-measuring device with an accuracy of ±1° C., and dialmicrometer having flat surfaces on both the anvil and the end of thespindle with a diameter of 6.4±0.2 mm (0.25±0.01 in) and exerting aforce of 300 g (weight as specified in the product standard). Testspecimens (mini wire line with covering, 25 mm (1″) length) were markedat the position where the foot of the weight is applied, and initialthickness determined. Test apparatus and specimens were conditioned inthe air oven at the specified temperature for 1 hour unless otherwisespecified. The specimen while in the oven is then placed under the footof the weight at the marked position for 1 hour unless otherwisespecified, then removed from under the foot of the weight and, within 15seconds, the thickness at the marked position is measured. Heatdeformation testing can be conducted according to UL 1581-2001. For eachformulation, two parallel sample plaques are preheated at 150° C. in anoven (1 hour), pressed with the same loading at 150° C. (1 hour) and,without removal of weights, placed in an ASTM room (23° C.) for 1 hour,and change of thickness of the plaques recorded and heat deformationratio calculated. The percent deformation (HD %) at a given testtemperature is calculated from the formula: HD %=(T1−T2)/T1*100 (formula‘b’), wherein T1 represents the original sample thickness (mm (in))before the test and T2 represents sample thickness(mm (in)) afterdeformation.

Heat Deformation/Plaque. Heat deformation testing is conducted accordingto UL 1581-2001. The test sample is cut from a compression molded (190°C.) plaque (1.44 mm thick). For each formulation, 2 parallel sampleplaques are preheated in an oven (150° C., 1 hour), pressed with sameloading (150° C., 1 hour), and, without removal of weights, placed in anASTM room (23° C.) for 1 hour. Change of thickness of the plaques isrecorded and heat deformation ratio calculated according to HD%=(D₀−D₁)/D₀*100%, wherein D₀=original sample thickness and D₁=samplethickness after deformation process. Calculated ratios for the twoparallel samples are averaged.

VW-1 Burn. This test is performed in accordance with the VW-1 FlameTest, Section 1080, of the UL-1581 testing standard, on the fabricatedwire or cable specimens to confirm resistance to vertical propagation offlame and dropping of flaming particles. The set up includes a specialBunsen burner with methane flame (ASTM 2556 standard). A nominal 20″long test specimen (50.8 cm) is supported in a vertical position withthe 500 watt burner flame impinging at a 45° angle near the base, acotton bed at the base establishes failure by flaming drip and a flag ontop shows failure at a given measured length to determine failure bypropagation of flame. Specimen ignition is by five 15-sec. exposures ofthe burner. An additional requirement is that the specimenself-extinguish within 60 sec. of the removal of the burner. Typically,3 specimens per sample are evaluated for the formulation screeningstudies. The wire or cable specimen from a mini-wire line is conditionedat room temperature (min. 24 hours) and straightened. A strip of Kraftpaper (12.5±1 mm (0.5±0.1″) wide), gum side toward the specimen, iswrapped once around the specimen with its lower edge about 254±2 mm(10±0.1″) above the point at which the inner blue cone of the flameimpinges on the specimen, and the ends pasted together evenly andtrimmed to form an indicator flag that projects about 20 mm (0.75 in)opposite to the side to which the flame is applied. On a flat specimen,the flag is projected from the center of the broad face of the specimen.The specimen, apparatus and surrounding air are at room temperature. Thelower specimen support is at least 50 mm (2 in) below the point at whichthe inner blue cone of the flame impinges on the specimen, and the uppersupport is at least 50 mm (2 in) above the top of the Kraft paper flag.A continuous horizontal layer of cotton is placed on the floor of thetest chamber, centered on the vertical axis of the test specimen,extending 75 to 100 mm (3 to 4 in) outward in all directions except inthe direction of the burner, with upper surface about 235±6 mm(9.25±0.25 in) below the point at which the tip of the blue inner coneof the flame impinges on the specimen. With the burner vertical, theheight of the test flame is adjusted to 125±10 mm (5.0±0.4 in), with aninner blue cone 40±2 mm (1.5±0.1 in) in length. The burner is thenpositioned on the angle block, with its barrel at an angle of 20° to thevertical. The angle block is moved into position with the tip of theinner blue cone of the flame impinging on the outer surface of thespecimen for 15 sec., and moved away for 15 sec.; this cycle is repeatedfor 5 applications of the flame using a smooth and quick movement of theangle block and minimal disturbance of the chamber air. When flaming ofthe specimen persists longer than 15 sec. after removal of the burnerflame, the burner flame is not re-applied until immediately after theflaming ceases. After the test is completed, the exhaust system isactivated to remove smoke and fumes from the chamber. During and afterthe test, the following is recorded: a) % indicator flag un-charred(from flag to first visible sign of physical damage other than simplyscorched or soot covered): the portion of the Kraft paper in contactwith the specimen is not considered part of the flag); b) any ignitionof the cotton; flameless charring of the cotton is typically ignored;and c) time for flaming of specimen to self-extinguish, after the end ofeach application of the burner flame. The results include the un-charredlength, any ignition of the cotton and indication if flaming of thespecimen exceeds 60 sec. after removal of the burner flame following anyapplication.

Flame Retardancy (FR). Mimic VW-1 FR test, which characterizes FRperformance, is conducted in an UL94 chamber with specimen size limitedto 200*2.7*1.9 mm. The specimens are hung on a clamp with longitudinalaxis vertical by applying 50 g loading on the distal end. One paper flag(2*0.5 cm) is applied on the top of the wire. The distance of flamebottom (highest point of the burner oracle) to the bottom of flag is 18cm. Flame is applied for 45 continuous seconds. After flame time (AFT),uncharred wire length (UCL), and uncharred flag area percentage (flaguncharred) is recorded during and after combustion. Four or fivespecimens are tested for each sample. Any of the following constitutes“not pass”: (1) cotton under the specimen is ignited, (2) the flag isburned out, and (3) dripping with flame.

Volume Resistivity (VR). A Hewlett-Packard High Resistivity Meter isused to measure volume resistivity. The conductance or resistance of amaterial is determined from a measurement of current or voltage dropunder specified conditions. By using the right electrode system, surfaceand volume resistance may be measured separately. Resistivity iscalculated using specimen dimensions. Product specimens are visuallyexamined for voids, creases, thin spots and cracks in the surface priorto punching them out; these imperfections in the plaque are avoided. A50-mil plaque cut into 3.5-in diameter discs is typically used. Testvoltage is set to 500V. For all VR measurements, 2 specimens wereprepared and tested in a 3 stage sequence: (1) vacuum dried at 80° C.(overnight) and tested, (2) 2-hour distilled water immersion (testspecimen #1 only), and (3) 48-hr. immersion and tested (test specimen #1only). Also, run specimen #2 directly at 48 hrs. after immersion inwater at room temperature. This is done to reduce work load and optimizelab efficiency by almost 33% without loosing critical details.

Wet Insulation Resistance. An about 10-meter length wire sample preparedby the Brabender tape extruder was tested for insulation resistance/wetinsulation resistance (IR/wet IR). Before testing, both ends of thejacketing are peeled off about 1.5 cm and the copper is twistedtogether. The sample was immersed in distilled water and 500 V DC wasapplied between conductor and the water during testing for both IR andwet IR. For IR testing, the wire sample was measured by withstandvoltage tester after applying the DC for one minute. For wet IR testing,the wire sample was immersed in water previously grounded for one hourand then measured in the same manner according to:

$\rho_{0} = {2,725 \times \frac{L \times R}{\lg\frac{D}{d}}}$

where ρ₀ is the insulation volume resistivity, expressed in ohmmillimetres; L is the immersed length of the test sample in millimetres;R is the measured insulation resistance in ohms; D is the outside cablediameter in millimetres; d is the conductor diameter in millimetres; and1 g is logarithm to the base 10.

Tables A, B and E (below) list formulations and properties of thefollowing composites of polypropylene/thermoplastic elastomers/flameresistant compounds (PP/TPE/FR). Examples IE are examples of theinvention and CE are comparative examples. Formulation components arereported in weight percent of the composition.

As shown in Table A and B, the inventive examples (IE) that are PPblended with a TPE and FP2100J N/P-based intumescent flame retardantcontaining a piperizine component, show both exceptional mechanicalproperties and flame retardant performance. Each inventive example (IE1-12) passed the mimic VW-1 flame resistance (FR) tests. Surprisingly,each of IE 1-12 have heat deformation at 150° C. at less than 50% and,at the same time, excellent tensile strength (>9 MPa) and elongation(>200%). In contrast, the comparative composites (CE 1-4) made with PP,TPE and a FR that did not include a piperazine component did not passthe mimic VW-1 flame resistance (FR) tests. In addition, as shown inTable A, CE-5 made with PP and FP2100J but without TPE passed the mimicVW-1 FR test but has a very high 5% secant modulus of 47850 psi, poorelongation (<15%) and poor heat deformation. With the presence of TPE(VERSIFY and/or SEBS) in examples IE-1 to IE-12, the 5% secant modulusdecreased below 33000 psi without loss of the heat deformation at 150°C.

Key customer specifications for halogen-free flame retardant (HFFR) wireand cable compositions include a tensile stress >5.8 MPa, tensileelongation >200% and heat deformation ratio <50% at 150° C. Theinventive samples (IE) were made by a Haake mixing process, andelongation would be further increased through twin-screw extrusionprocessing

TABLE A Component (wt %) IE-1 IE-2 IE-3 IE-4 IE-5 IE-6 CE-1 CE-2 CE-3CE-4 CE-5 PP 6D83K — — — — — — 44.0 44.0 44.0 44.0 — PP(C715-12) 27.027.0 36.0 30.0 27.0 24.0 — — — — 60 VERSIFY DE3300 — — — — — — 11.0 11.011.0 11.0 — VERSIFY DP3200 33.0 — — — — — — — — — — VERSIFY DP4200 —33.0 — — — 36.0 — — — — — VERSIFY DE4301 — — 24.0 30.0 33.0 — — — — — —APP CROS C30 — — — — — — 30   22.5 22.5 30   — MPP Budit 311 — — — — — —15   22.5 — — — MPP Budit 3141 — — — — — — — — 22.5 15   — FP2100J 40.040.0 40.0 40.0 40.0 40.0 — — — — 40 Total 100 100 100 100 100 100 100  100   100   100   100 Tensile Strength, Mpa 11.1 11.1 12 11 12.9 14.416*   13.5*  12.6*  14.4* 15.6 Tensile Strength, psi 1609.5 1609.5 17401595 1870.5 2088 2323*   1957.5*  1827*   2088*   2260 Elongation, % 491476 468 497 568 580 416*   313*   206*   321*   15 HD @150° C. 22 19 216 44 30 23   20   23   24   — 5% Secant Modulus, 202 191 227 191 157182 280*   279*   288*   283*   330 Mpa 5% Secant Modulus, Psi 2929027695 32915 27695 22765 26390 40600*    40455*    41760*    41035*   47850 Mimic VW-1(Pass/Total) 5/5 6/6 5/5 5/5 4/4 5/5 0/4* 0/4* 0/4* 0/4*4/4 Tensile Speed: 500 mm/min *Tensile speed: 50 mm/min

TABLE B Component (wt %) IE-7 IE-8 IE-9 IE-10 IE-11 IE-12 PP(C715-12)30.0 20.0 20.0 20.0 23.0 27.0 SEBS(G1643M) 30.0 — 10.0 25.0 27.0 17.0SEBS(G1651ES) — 40.0 30.0 15.0 10.0 — VERSIFY DE 4301 — — — — — 16.0FP2100J 40.0 40.0 40.0 40.0 40.0 40.0 Total 100 100 100 100 100 100Tensile Strength, Mpa 9.3 11.6 13.6 11 9.9 9.2 Tensile Strength, psi1348.5 1682 1972 1595 1435.5 1334 Elongation, % 500 393 560 590 573 485HD @150° C. 37 4 9 26 33 9 5% Secant Modulus, Mpa 103 105 89 52 68 1525% Secant Modulus, psi 14935 15225 12905 7540 9860 22040 MimicVW-1(Pass/Total) 4/4 4/4 4/4 4/4 4/4 4/4 Tensile Speed: 500 mm/min

Table C and Table D (below) list formulations and properties of thecomposites of PP/TPE/FR compounds.

The typical criteria used for W&C applications includes passing the VW-1test for flame retardancy, heat deformation at 121° C. at <50%, andflexibility at <35,000 psi. In Table C, IE 1 and IE 2 show overallwell-balanced properties including good flexibility, high flameresistance, high heat deformation and good wet electrical properties. CE1 through CE 3 made with TPE(s) and the FR system without piperazineexhibited un-balanced properties. CE 1, a blend of OBC and VERSIFYresulted in low tensile strength and poor flame resistance. CE 2, ablend of ULDPE and VERSIFY had low tensile strength and poor heatdeformation. IE 1 also demonstrates the use of BAPP with another solidintumescent FR provides good flame resistance and good flexibility. CE 3is a single resin system which showed poor heat deformation performanceat 121° C.

TABLE C IE 1 IE 2 CE 1 CE 2 CE 3 OBC INFUSE D9530 — — 29.90 — — VERSIFY3000 45.80 49.80 29.90 29.90 — VERSIFY 3200 — — — — 65.8 ULDPE (Attane4404G) — — — 29.90 — Dow DS6D82 random PP 10.00 10.00 — — — Budit 3167(std., 14 μm) 40.00 40.00 40.00 40.00 30 Chemtura BAPP 4.00 — — — 4Irganox 1010 0.20 0.20 0.20 0.20 0.2 Tensile Strength @ Peak (psi) 18131953 1336 1040 2175 Tensile Elongation @ Break 559 524 602 423 690 5%Secant Modulus (psi) 14540 24176 17752 20372 8222 VW-1(pass/fail) P P FP F Heat Distortion (%, 80 C.) — — 0 8 11.7 Heat Distortion (%, 121 C.)34 28 86 77 100 Wet VR (Soak 48 hr, ohm cm) 2.8E+14 4.9E+16 1.8E+164.3E+16 2.4E+15

In Table D (below), IE 3 through IE 6 show well-balanced properties aswith IE 1 and IE 2, and unexpectedly have even lower secant modulus thanIE 1 but comparable heat deformation performance. VERSIFY 3200, VERSIFY3300, VERSIFY 2400 are the primary resins in IE 2 through IE 4, and itwas unexpected that the blends with a primary phase of meltingtemperature (melting point, m. pt.) less than 85° C. exhibited good heatdeformation at high temperatures of 121° C.

The loading level of intumescent FRs in IE 3 to IE 5 are much lower thanthe typical loading level required for VW-1 performance in otherpolyolefin-based formulations composed of intumescent N—P FRs without apiperazine component. The surprisingly good flame resistance in IE 3 toIE 5 indicates a burn synergist effect between the polymer resins andthe FR packages used in IE 3 to IE 5. This effect is furtherdemonstrated by CE 4 using an alternative intumescent FR (without apiperazine component), which exhibited poor flame resistance and did notmeet VW-1 performance requirement. Compared to the high volumeresistivity in IE 3 through IE 5, CE 4 also exhibited poor wetelectrical properties.

TABLE D IE 3 IE 4 IE 5 IE 6 CE 4 VERSIFY 3300 (m. pt = 62° C.) 35.8 — —— — VERSIFY 3200 (m. pt = 85° C.) — 40.8 — 30.8 40.8 VERSIFY 2400 (m. pt= 55° C.) — — 36.1 — — Dow DS6D82 random PP 30 25 28.7 25 25 Budit 3167(standard, 14 μm) 30 30 29 40 — BAPP 4 4 4 4 4 Budit FR CROS 30 (without— — — — 30 piperazine component) Dynasylan 6498 — — 2 — — Irganox 10100.2 0.2 0.2 0.2 0.2 Peak stress (psi) 1698 2245 2467 1732 2329Elongation at break (%) 635 657 774 590 552 5% Secant modulus (psi)10734 9408 7523 10268 14363 VW-1(pass/fail) P P P P F Heat deformation(%, 121 C.) 46.8 44 40.5 22 52.1 Wet VR (ohm · cm, 48 hr soak) 3.3E+153.4E+15 3.9E+15 4.6E+14 <4.1E+09

Table E (below) lists formulations and properties of the composites ofPP/TPE/FR compounds. The inventive samples (IE) are made by a Haakemixing process and followed by compression molding, and elongation wouldbe further increased through twin-screw extrusion processing. Injectionmolding is conducted on FANUC 100 ton high speed with mold temperatureof 50° C. and a temperature profile of 200, 210, 205, 200, 190, 50° C.for mechanical testing.

In Table E, IE1-IE7 include high melting point VERSIFY 2400.05 which hasa melting point greater than 130° C. These examples pass the HDrequirement at a PP loading of 24%. The required PP loading may befurther reduced to 21% if homoPP (H110-02N) is used. For different P—Nintumescent FR packages, all the inventive samples show a robust FRperformance. IE8-IE9 includes VERSIFY 2400 with a melting point below130° C. With a PP loading of 24%, IE8 did not pass the HD requirement.However, if the PP loading for IE8 is increased to 27%, as in IE 9, thenthe example passes the HD requirement. As can be seen in Table E, alower amount of polypropylene is needed in compositions that use highmelting point VERSIFY (IE-1 through IE-7), than those which use VERSIFY2400 (IE-8 and IE-9) having a melting point below 130° C.

TABLE E IE-1 IE-2 IE-3 IE-4 IE-5 IE-6 IE-7 IE-8 IE-9 PP H110-02N 24 — 24— 21 24 24 — — PP C715-12 — 24 — 24 — — — 24 27 VERSIFY 2400.05 36 36 3636 39 36 36 — — VERSIFY 2400 — — — — — — — 36 33 Si-Oil — — 3 3 — — — —— EVA 265 — — — — — — — — — JLS PNP1D 34 34 31 31 34 — — 34 34 Melamine3 3 3 3 3 — — 3 3 PER 2 2 2 2 2 — — 2 2 ZnO 1 1 1 1 1 — — 1 1 FP2100J —— — — — 40 — — — Budit 3167 — — — — — — 40 — — Irganox 1010 0.3 0.3 0.30.3 0.3 0.3 0.3 0.3 0.3 Irgafos 168 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1Total 100.4 100.4 100.4 100.4 100.4 100.4 100.4 100.4 100.4 TS, MPa 15.212.87 14.5 11.7 14.3 16.4 14.0 7.9 7.5 TE, % 693 597 746 673 737 662 618456 598 HD, % 10 16 17 17 39 9 11 57 11 Mimic VW-1, 3/3 3/3 3/3 3/3 3/33/3 3/3 3/3 3/3 Pass/Total Sag No No No No No No No No No Dripping No NoNo No No No No No No

Table F (below) shows the performance data for injection molding andwire coating for examples IE-10 through IE-11. IE-10 and IE-11, whichcomprise the high melting point VERSIFY 2400.05, pass all of therequirements. In particular, the tensile elongation is more than 200%.In contrast, IE12, which comprises VERSIFY 2400 with a relatively higherPP loading, also passes the HD requirement, however, affords poortensile elongation and failed to meet the UL-62 requirement. Not wishingto be bound by theory, the poor tensile elongation resulting from higherPP loading may be due to the orientation of the PP crystals duringinjection molding.

Therefore, the incorporation of high melting point VERSIFY 2400.05affords superior flame retardant performance allowing for a lower PPloading. In addition, the incorporation of the high melting pointVERSIFY results in lower density than TPU-based HFFR and the rawmaterial cost of composites using the high melting point VERSIFY aresignificantly decreased.

TABLE F IE-10 IE-11 IE-12 VERSIFY 2400.05 36 36 — VERSIFY 2400 — — 33 PP715-12 24 24 27 JLS PNP1D 31 34 — Silicon oil 3 — — ZnO 1 1 — Melamine 33 — PER 2 2 — FP2100J — — 40 Irganox 1010 0.8 0.8 0.8 Irganox PS802 0.20.2 0.2 Irgafos 168 0.1 0.1 0.1 Irganox MD1024 0.2 0.2 0.2 Total 101.3101.3 101.3 HD (Plaque) 5 6 10.4 TS, MPa (Plaque) 14.8 15.4 16.9 TE, %(Plaque) 230 233 99 Mimic VW-1, Pass/Total 5/5 5/5 5/5 TS, MPa, Wire11.3 n/m* n/m* TE, % Wire 577 n/m* n/m* HD, Wire 27% n/m* n/m* *notmeasured

Although the invention has been described with certain detail throughthe preceding specific embodiments, this detail is for the primarypurpose of illustration. Many variations and modifications can be madeby one skilled in the art without departing from the spirit and scope ofthe invention as described in the following claims.

What is claimed is:
 1. A halogen-free flame-retardant polymercomposition, comprising: a) greater than 20 wt % to less than or equalto 30 wt % of a propylene polymer, based on total weight of thecomposition; b) a thermoplastic elastomer (TPE) having a meltingtemperature of greater than 130° C.; and c) an intumescent flameretardant system comprising a piperazine component, the compositionhaving a heat deformation of less than 50% as determined according to UL1581-2001.
 2. The composition of claim 1 in which the flame retardantsystem comprises an organic phosphoric acid salt intumescenthalogen-free flame retardant.
 3. The composition of claim 1 in which thepiperazine component is selected from the group consisting of piperazinepyrophosphate, piperazine orthophosphate, piperazine polyphosphate, apolytriazinyl compound comprising a piperazine group, and an oligomer orpolymer 1,3,5-triazine derivative comprising a piperazine group.
 4. Thecomposition of claim 1 in which the flame retardant system comprises (A)a blend of nitrogen-phosphorus intumescent compound and piperazinepyrophosphate, (B) an ammonium polyphosphate intumescent compound with apiperazine component, (C) a blend of (1) ammonium polyphosphate, (2) apiperazine compound, and (3) a melamine coating, or (D) a combinationthereof.
 5. The composition of claim 1 in which the thermoplasticelastomer is selected from the group consisting of styrenic blockcopolymers, propylene/α-olefin copolymers, ethylene/α-olefin copolymers,ethylene interpolymers, and olefin block copolymers.
 6. The compositionof claim 1 comprising greater than 20 wt % to less than or equal to 24wt % propylene polymer, 20-40 wt % thermoplastic elastomer, and 10-70 wt% flame retardant system, based on the total weight of the composition.7. The composition of claim 1 in which the flame retardant systemcomprises 1-99 wt % piperazine based flame retardant and 1-99 wt % of anorganic phosphoric acid salt intumescent halogen-free flame retardant,based on the total weight of the flame retardant system.
 8. A wire orcable sheath made from the composition of claim
 1. 9. The wire or cablesheath of claim 8 having flame retardancy effective to pass VW-1 test, aheat deformation effective to pass UL1581-2001 test at 150° C.